Woven mat with boot scraper

ABSTRACT

A woven mat with bootscraper, having a woven base; at least six brushes in communication with the woven base and at least two coir brushes at each end of the woven base; at least three plastic pieces in communication with the woven base and each of the at least three ridge pieces is between at least two of the coir brushes; an attachment means for attaching the at least six coir brushes and the at least three ridged plastic pieces to the woven base.

This is a continuation in part and claims priority to international application number PCT/IN2004/000371 filed Dec. 1, 2004 which is currently pending.

This invention in general relates to textile technology. This invention generally relates to manufacturing of doormats, doormats with or without latex backing. In particular this invention relates to doormats made of coir and polypropylene and their manufacture.

Doormats made of coir are biodegradable, rugged and firm offering utility in both indoor and outdoor settings. When a doormat is made using coir and polypropylene and conventional weaving, the product becomes even more versatile and affordable for scraping and ruggedness. It offers high utility and convenience of usage. It is an innovative product and a revolutionary concept in the category of hand woven doormats.

According to one object of invention a method is provided to improve the product so that it is unique, rugged and economical. Another object of the invention is to employ traditional and conventional method of weaving in order to manufacture doormats. Another object of the invention is to employ rubber being natural product as raw material for manufacture of doormats. Another object of invention is to invent a novel method of manufacturing doormats, which provide increased softness.

Accordingly, the present invention provides a woven rubber mat with a boot scraper.

SUMMARY OF THE INVENTION

The present invention relates generally to doormats having a bootscraper and their methods of manufacture.

According to one aspect of the present invention, a woven mat with bootscraper is provided, the woven mat comprising: a woven base; at least six brushes in communication with the woven base and having at least two coir brushes at each end of the woven base; at least three plastic pieces in communication with the woven base and each of the at least three ridge pieces is between at least two of the coir brushes; an attachment means for attaching the at least six coir brushes and the at least three ridged plastic pieces to the woven base.

A woven mat with bootscraper, said woven mat comprising: a woven base; eight brushes in communication with the woven base; four plastic pieces in communication with the woven base; an attachment means for attaching the eight brushes and four plastic pieces to the woven base to provide in order two of brushes, one plastic piece, one brush, one plastic piece, one brush, one plastic piece, one brush, one plastic piece and two brushes.

A method of manufacturing mat having woven boot scrapper which comprises of following steps: providing a first beam for coir yarns; providing a second beam for polypropylene yarns; drawing three coir warp threads and one polypropylene threads through the mail eye of the heald; drawing three coir warp threads and one polypropylene thread through the read space; tieing the three coir warp threads and one polypropylene thread on a cloth roller; drawing the ends of the three warp threads and the one polypropylene threads through the fifth reed; repeating to provide a mat of desired width; connecting the mat to a corresponding treadle according to the tie up and treadling plan; providing coir yarn for warp and weft; providing coir brush polypropylene yarn for locking; providing a 2/2 panama weave base; providing three shafts, wherein a first shaft and second shafts are used for 2/2 panama weave base and a third shaft is for polypropylene yarns; forming two series boucle weave product; pressing the third shaft to raise the polypropylene yarns as a loop; inserting the coir brush into the loop; pulling down the first shaft to raise a corresponding series of warp threads; inserting weft by passing of shuttles and being of sley fixed in a well manner; pulling down the second shaft; raising the series of warp; inserting the weft; beating the sley; raising the third shaft polypropylene yarns; inserting the coir brush below the threads to lock; pressing the first shaft and the second shaft to insert two series of weft forming a groove between coir brushes; pressing the third shaft to raise the polypropylene yarns and insert the coir brush; repeating to provide a mat.

These and other features, aspects and advantages of the present invention will become better understood with reference to the following description and claims.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 depicts a mat according to the present invention;

FIG. 2 depicts a mat according to the present invention;

FIG. 3 depicts a mat according to the present invention; and

FIG. 4 depicts a mat according to the present invention.

DETAILED DESCRIPTION OF THE INVENTION

The following detailed description is of the best currently contemplated modes of carrying out the invention. The description is not to be taken in a limiting sense, but is made merely for the purpose of illustrating the general principles of the invention, since the scope of the invention is best defined by the appended claims.

As shown in FIGS. 1-4, a woven mat with bootscraper (10) is provided, the woven mat comprising: a woven base (12); eight brushes (14, 16, 18, 20, 22, 24, 26, 28) in communication with the woven base (12); five plastic pieces (30, 32, 34, 36, 38) in communication with the woven base (12); an attachment means (40) for attaching the eight brushes (30, 32, 34, 36, 38) and the four plastic pieces (30, 32, 34, 36, 38) to the woven base (12) to provide in order two of brushes (14, 16) one plastic piece (30), one brush (18) one plastic piece (32), one brush (20), one plastic piece (34), one brush (22), one plastic piece (36), one brush (24), one plastic piece (38 two brushes (26, 28). Having two brushes (14, 16 and 26, 28) at either side is important because it provides increased stability and better brushing of the shoes or boots. In this way, the shoes or boots of the wearer are cleaned off much more efficiently and the mat is more rugged. The attachment means (40) may be coir yarn. It is envisioned that many means could be used including wire, yarn, etc. without departing from the scope of the present invention. The brushes may be coir brushes made of thread wound in 14-16 mm galvanized metal wire. The plastic pieces (30, 32, 34, 36, 38) are ridged. As shown in FIG. 2, it may be desirable to have the ridged pieces ridges run horizontal to provide maximum scraping and brushing. The term run horizontal refers to the manner in which the product would be used with FIG. 2 depicting the manner in which the product would be used with the user brushing their foot towards the bottom brush 28 to remove debris and liquid.

The present invention provides a method of manufacturing a mat (10) having woven boot scrapper which comprises of following steps: providing a first beam for coir yarns; providing a second beam for polypropylene yarns; drawing three coir warp threads and one polypropylene threads through the mail eye of the heald; drawing three coir warp threads and one polypropylene thread through the read space; tieing three coir warp threads and the one polypropylene thread on a cloth roller; drawing the ends of the three warp threads and the one polypropylene threads through the fifth reed; repeating to provide a mat of desired width; connecting the mat to a corresponding treadle according to the tie up and treadling plan; providing coir yarn for warp and weft; providing coir brush polypropylene yarn for locking; providing a 2/2 panama weave base; providing three shafts, wherein a first shaft and second shafts are used for the 2/2 panama weave base and a third shaft is for polypropylene yarns; forming two series boucle weave product; pressing the third shaft to raise the polypropylene yarns as a loop; inserting the coir brush into the loop; pulling down the first shaft to raise a corresponding series of warp threads; inserting weft by passing of shuttles and being of sley fixed in a well manner; pulling down the second shaft; raising the series of warp; inserting the weft; beating the sley; raising the third shaft polypropylene yarns; inserting the coir brush below the threads to lock; pressing the first shaft and the second shaft to insert two series of weft forming a groove between coir brushes; pressing the third shaft to raise the polypropylene yarns and insert the coir brush; repeating to provide a mat. The coir brush may be manufactured by: providing a galvanized metal wire; hooking a first end of the galvanized metal wire on a wire twister; hooking a second end of the galvanized metal on a hand-rotating device; arranging fibres in a tray according to the desired height; placing the tray beneath the galvanized metal wire and between a hook and the hand rotating device, wherein the hand rotating device twists capturing the fibres to provide a coir brush. The ply and diameter of coir yarn and polypropylene yarn are changed according to the requirement of square metre weight of the product.

It should be understood that the foregoing relates to preferred embodiments of the invention and that modifications may be made without departing from the spirit and scope of the invention as set forth in the following claims. 

1. A woven mat with bootscraper, said woven mat comprising: a woven base; at least six brushes in communication with said woven base and having at least two coir brushes at each end of said woven base; at least three plastic pieces in communication with said woven base and each of said at least three ridge pieces is between at least two of said coir brushes; an attachment means for attaching said at least six coir brushes and said at least three ridged plastic pieces to said woven base.
 2. A woven mat with bootscraper as in claim 1, wherein said attachment means is coir yarn.
 3. A woven mat with bootscraper as in claim 1, wherein said at least six coir brushes are coir thread wound in 14-16 mm galvanized metal wire.
 4. A woven mat with bootscraper as in claim 1, wherein said at least three plastic pieces are ridged having more than one ridge.
 5. A woven mat with bootscraper as in claim 4, wherein said ridges run horizontal.
 6. A woven mat as in claim 1, wherein said at least six brushes are coir brushes.
 7. A woven mat with bootscraper, said woven mat comprising: a woven base; eight brushes in communication with said woven base; five plastic pieces in communication with said woven base; an attachment means for attaching said eight brushes and said five plastic pieces to said woven base to provide in order two of said brushes, one said plastic piece, one said brush, one said plastic piece, one said brush, one said plastic piece, one said brush, one said plastic piece, one said brush, one said plastic piece and two said brushes.
 8. A woven mat with bootscraper as in claim 7, wherein said attachment means is coir yarn.
 9. A woven mat with bootscraper as in claim 7, wherein said eight brushes are coir brushes made of thread wound in 14-16 mm galvanized metal wire.
 10. A woven mat with bootscraper as in claim 7, wherein said five plastic pieces are ridged having more than one ridge.
 11. A woven mat as with bootscraper as in claim 10, wherein said ridge runs horizontal
 12. A woven mat as in claim 1, wherein said eight brushes are coir brushes.
 13. A method of manufacturing mat having woven boot scrapper which comprises of following steps: providing a first beam for coir yarns; providing a second beam for polypropylene yarns; drawing three coir warp threads and one polypropylene threads through the mail eye of the heald; drawing three coir warp threads and one polypropylene thread through the read space; tieing said three coir warp threads and said one polypropylene thread on a cloth roller; drawing the ends of said three warp threads and said one polypropylene threads through the fifth reed; repeating to provide a mat of desired width; connecting said mat to a corresponding treadle according to the tie up and treadling plan; providing coir yarn for warp and weft; providing coir brush polypropylene yarn for locking; providing a 2/2 panama weave base; providing three shafts, wherein a first shaft and second shafts are used for said 2/2 panama weave base and a third shaft is for polypropylene yarns; forming two series boucle weave product; pressing said third shaft to raise said polypropylene yarns as a loop; inserting said coir brush into said loop; pulling down said first shaft to raise a corresponding series of warp threads; inserting weft by passing of shuttles and being of sley fixed in a well manner; pulling down said second shaft; raising said series of warp; inserting said weft; beating said sley; raising said third shaft polypropylene yarns; inserting said coir brush below said threads to lock; pressing said first shaft and said second shaft to insert two series of weft forming a groove between coir brushes; pressing said third shaft to raise said polypropylene yarns and insert said coir brush; repeating to provide a mat.
 14. A method of manufacture as in claim 13, wherein said coir brush is manufactured by: Providing a galvanized metal wire; Hooking a first end of said galvanized metal wire on a wire twister; Hooking a second end of said galvanized metal on a hand-rotating device; Arranging fibres in a tray according to the desired height; Placing said tray beneath said galvanized metal wire and between a hook and said hand rotating device, wherein said hand rotating device twists capturing said fibres to provide a coir brush.
 15. A method of manufacturing mat as in claim 13, wherein the ply and diameter of coir yarn and polypropylene yarn are changed according to the requirement of square metre weight of the product. 